2.
Remove the inlet upper manifold assembly (A) (Refer to "Intake and Exhaust system" in EM group).
As the Piezo-Injector operates under maximum DC 200V, there may be a risk of an electric shock caused by shorted control line etc. So when repairing the injector or its wiring, disconnect the battery negative (-) terminal from the battery and wait for about 30 seconds.
Common Rail Fuel Injection System operates with extremely high pressure (approximately 1,600bar), so never perform any work on injection system with engine running or within 30 seconds after the engine stops.
Keep cleanly the parts and the working area.
Pay attention to a foreign substance.
Just before installing injector, tube or hose, remove the protect-cap attached on them.
Do not remove injector except for special case.
When installing Injector
- Wash the contact area of the injector and replace the O-ring with a new one.
- Spread oil on the injector O-ring.
- To protect damage caused by shock, vertically insert the injector into the cylinder head.
When installing High Pressure Fuel Pipe
- Do not use again the used high pressure fuel pipe.
- Install the flange nut correctly.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
Remove the inlet upper manifold assembly (A) (Refer to "Intake and Exhaust system" in EM group).
Disconnect the rail pressure sensor connector (A).
Disconnect the fuel feed and the return tube quick-connector (B).
Remove the high pressure fuel pipes (C).
Unscrew the mounting bolts (D), and then remove the common rail from the engine.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
Remove the intercooler pipe and the hose (Refer to "Intake and Exhaust system" in EM group).
Disconnect the rail pressure regulator valve connector (A).
Disconnect the fuel return tube quick-connector (B).
Remove the high pressure fuel pipes (A).
Unscrew the mounting bolts (B), and then remove the common rail from the engine.
